Textron Greenlee 1990 Bedienungsanleitung

OPERATION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

1990

Hydraulic Crimping Tool

Serial CodeYM

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

1990 Hydraulic CrimpingTool

Table of Contents

Description .....................................................................2

Safety.............................................................................2

Purpose of this Manual ..................................................2

Important Safety Instructions......................................3-4

Identification................................................................... 5

Specifications.................................................................5

Operation ....................................................................6-7

cUL and UL Classified Crimps.......................................8

Periodic Pressure Relief Valve Check...........................9

Maintenance ..................................................................9

Troubleshooting ...........................................................10

Air Purging and Oil Filling Procedure ..........................11

Exploded View .............................................................12

Parts List ......................................................................13

Description

The 1990 Hydraulic Crimping Tool is a hand-held, self-

contained dieless crimping tool intended to crimp

aluminum and copper connectors onto electrical cable.

The hinged crimping head, which allows easy loading

and unloading of splice connections, swivels 180°for

maximum flexibility. The two-speed hydraulic system

automatically switches from rapid advance (for quick

snug-up) to normal advance (to accomplish the crimp).

An internal pressure regulating system automatically

sets the correct pressure for the connector.

This tool is cUL and UL classified for use as directed on

the cUL/UL Table provided in this manual and on the

carrying case.

The 1990 Crimping Tool is protected by US Patent No.

4,796,461.

Safety

Safety is essential in the use and maintenance of

Greenlee tools and equipment. This manual and any

markings on the tool provide information for avoiding

hazards and unsafe practices related to the use of this

tool. Observe all of the safety information provided.

Purpose of this Manual

This instruction manual is intended to familiarize all

personnel with the safe operation of the Greenlee 1990

Hydraulic Crimping Tool.

Keep this manual available to all personnel.

Replacement manuals are available upon request at no

charge.

KEEPTHIS MANUAL

All specifications are nominal and may change as design improve-

ments occur. Greenlee Textron shall not be liable for damages

resulting from misapplication or misuse of its products.

Blackburn is a registered trademark of Thomas & Betts Corporation.

Dow Corning is a registered trademark of Dow Corning Corporation.

RTV Sealant 732 is a trademark of Dow Corning Corporation.

UL is a registered trademark of Underwriter’s Laboratories,

Incorporated.

UNIVIS is a registered trademark of Exxon Corporation.

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

1990 Hydraulic CrimpingTool

IMPORTANT SAFETY INFORMATION

Inspect tool before use. Replace any worn or

damaged parts. A damaged or improperly

assembled tool can break and strike nearby

personnel.

Failure to observe this warning can result in

severe injury or death.

An incomplete crimp can cause a fire.

• Use proper connector and cable combinations.

Improper combinations can result in an incom-

plete crimp.

• The relief valve will sound to indicate a com-

pleted crimp. If you do not hear the sound of the

relief valve, the crimp is not complete.

Failure to observe these warnings can result in

severe injury or death.

Electric shock hazard:

This tool is not insulated. When

using this unit near energized

electrical lines, use proper personal

protective equipment.

Failure to observe this warning can

result in severe injury or death.

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection can

result in serious eye injury from

flying debris or hydraulic oil.

Skin injection hazard:

Oil under pressure easily punctures

skin causing serious injury, gan-

grene or death. If you are injured by

escaping oil, seek medical attention

immediately.

• Do not use hands to check for

leaks.

• Depressurize the hydraulic system

before servicing.

This symbol is used to call your attention to hazards

or unsafe practices which could result in an injury

or property damage. The signal word, defined below,

indicates the severity of the hazard. The message

after the signal word provides information for

preventing or avoiding the hazard.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

Hazards which, if not avoided, COULD result in

severe injury or death.

Immediate hazards which, if not avoided, WILL result

in severe injury or death.

SAFETY

ALERT

SYMBOL

Read and understand all of the

instructions and safety information

in this manual before operating or

servicing this tool.

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

1990 Hydraulic CrimpingTool

IMPORTANT SAFETY INFORMATION

Note: Keep all decals clean and legible. Replace decals

when necessary.

Keep hands away from the crimping

tool head when crimping.

•This tool is intended for two-handed operation.

Maintain a firm grip on both handles during

operation. Using this tool in any other manner can

result in injury or property damage.

•Do not perform any service or maintenance other

than as described in this manual. Injury or damage

to the tool may result.

Failure to observe these precautions can result in

injury and property damage.

Greenlee / A Textron Company 54455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070

1990 Hydraulic CrimpingTool

Identification

Specifications

Crimping Tool

Length..................................................................................... 673 mm (26.5")

Width...................................................................................... 26.3 mm (2.87")

Mass/Weight ............................................................................ 7.5 kg (16.5 lb)

Hydraulic Oil ............................................................................. 198 cc (12 in3)

Crimping Capacities

Crimping Range

Copper Connectors ............................25–500 mm2(4 AWG–1000 kcmil)

Aluminum Connectors ........................16–500 mm2(6 AWG–1000 kcmil)

Maximum Crimper Diameter.......................................... 461 mm (1.815")

Crimping Force (maximum) .................................................. 133 kN (15 tons)

Crimping Tool Adjusts Automatically to Connector Size

MOVABLE

PIN UNIT

RELEASE

TRIGGER

RAM DIE

DIE HEAD

Greenlee / A Textron Company 64455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070

1990 Hydraulic CrimpingTool

Operation

Preparation

1. Select a proper size and type of connector to

correspond with the wire or cable.

2. Strip the cable to an appropriate length. Follow the

connector manufacturer’s instructions.

Note: Apply an oxide inhibitor, if required. See the

connector manufacturer’s instructions.

Crimping

1. Insert the cable fully into the connector.

2. Position the connector in the crimping head.

Note: Position lug connectors so the tang is

perpendicular to the direction of ram travel, as

shown.

Electric shock hazard:

This tool is not insulated. When

using this unit near energized

electrical lines, use proper personal

protective equipment.

Failure to observe this warning can

result in severe injury or death.

Wear eye protection when operating

this tool.

Failure to wear eye protection can

result in serious eye injury from

flying debris or hydraulic oil.

Inspect tool before use. Replace any worn or

damaged parts. A damaged or improperly

assembled tool can break and strike nearby

personnel.

Failure to observe this warning can result in

severe injury or death.

An incomplete crimp can cause a fire.

•Use proper connector and cable combinations.

Improper combinations can result in an incom-

plete crimp.

•The relief valve will sound to indicate a com-

pleted crimp. If you do not hear the sound of the

relief valve, the crimp is not complete.

Failure to observe these warnings can result in

severe injury or death.

For a cUL or UL classified crimp, see the connec-

tor table in this instruction manual.

Keep hands away from the crimping

tool head when crimping.

DIRECTION OF RAM TRAVEL

TANG

Greenlee / A Textron Company 74455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070

1990 Hydraulic CrimpingTool

Operation (cont’d)

3. If open, close the die head and push in the movable

pin unit. Make sure the movable pin is fully

engaged.

4. Align the tool with the alignment mark (for lugs) or

center stop (for sleeves) as shown.

5. Pump the handle to advance ram. Continue to

pump until the pressure relief valve activates.

Note: Pressure relief is indicated by an audible

“pop”and a sudden drop in handle force.

6. To release the hydraulic pressure, pull the release

trigger back while pressing down on the handle.

Note: To prevent the ram from retracting

completely, release the trigger. This speeds the

crimping process when a single connector requires

several crimps.

7. For a cUL or UL classified crimp, complete the

number of crimps specified in the cUL/UL Table.

Note: For brands not listed, consult the connector

manufacturer’s instructions to determine the number

of crimps and the acceptability of installation with a

dieless tool.

8. To remove the tool from a splice, pull the movable

pin on the die head and open the crimping head.

OUTERMOST

BLADE OF DIE HEAD

LUG

ALIGNMENT

MARK

LONGER LUG

TANG

OUTERMOST

BLADE OF RAM DIE

LUG

ALIGNMENT

MARK

SHORTER LUG

TANG

OUTERMOST

BLADE OF DIE HEAD

CENTER

STOP

SLEEVE

Greenlee / A Textron Company 84455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070

1990 Hydraulic CrimpingTool

cUL and UL Classified Crimps

The 1990 Hydraulic Crimping Tool is cUL and UL classified* for use with the following connectors:

cUL/ULTable

ROTCENNOC

EPYT NOSREDNANRUBKCALB



YDNRUBICFOCSLI**B&T ENYDELET

NOINU-NNEP

①ERIW

EZIS

FO.ON

***SPMIRC

detaRlauD munimulA seveelS SCAVPSAA-SYSA48506–70506KIP –GWA6 GWA0/4 1

detaRlauD munimulA sguL LCAVLTA A-AY NTA-AY NCA/LCA NCA2/LCA2 48106–60106 48206–03206 AULB

–limck052 limck0001 roreppoC munimulA

reppoC seveelS SSHV/SHVUC/PSCL-SY/SYLTC/TC 82545–60545 82845–60845 UCB UCBB –GWA4 limck0001 reppoC 1

sguLreppoCLCHV 2-LTC NLC/L-LTC LTC

L2-AY/L-AY/AY N2-AY/NL2-AY CT2-L-AY/CT-L-AY

BRC/ARC L-BRC/L-ARC L2-ARC L2-BRC

82145–60145 82245–60245 82945–60945 28845–45845

ULB ULBB

munimulA niP rotcennoC PEC— PYA

MCA –GWA6 limck0001 LA

—PT–GWA6 limck057 munimulA 1

munimulA tesffO rotcennoC OPEC— OPYA

OCA –GWA6 limck0001 LA

—OPT –GWA6 limck057 munimulA 1

reppoC liatgiP retpadA —— —

MPC

——

–GWA6 limcK005 munimulA

UC9LAMPC

–GWA6 limck005 roreppoC munimulA

①

*****

.srotcudnocmunimuladnareppocdednartshtiwesuroF

DETONSATPECXE

.srotcudnocmunimuladnareppocdednartstcapmocrodesserpmoc,cirtnecnocdradnatshtiwdesunehW .0991ehtfoyticapacdetarehtnihtiwezisrotcennocahtiwdesunehwylnO .rotcennocehthtiwdedivorprebmunfodaetsninmulocsihtnidetsilspmircforebmunehtesu,0991ehthtiwgnipmircnehW

95R7

Greenlee / A Textron Company 94455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070

1990 Hydraulic CrimpingTool

Periodic Pressure Relief Valve Check

Test the crimping tool periodically to ensure that the

pressure relief valve activates at the proper pressure.

Order crimping tool test kit, Greenlee part number

503 2891.3.

Testing the Crimping Tool

1. Center a new pressure test slug in the crimping

head.

2. Pump the handles to advance ram. Continue to

pump until the pressure relief valve activates.

3. To release the hydraulic pressure, pull the release

trigger back while pressing down on the handle.

4. Repeat Steps 1–3 on two more test slugs.

5. Test the three slugs as follows against the GO/NO

GO gauge as shown.

•If the GO slot will fit over the slug and the NO GO

slot will not, the pressure is within the specified

range.

•If the GO slot will not slide over the slug, the

crimping pressure is too low. Send the crimping

tool to an authorized service center.

•If the NO GO slot will slide over the slug, the

crimping pressure is too high. Send the crimping

tool to an authorized service center.

The pressure test slugs are manufactured to a

precise diameter and hardness. Do not re-use the

test slugs. Discard each slug after use.

Maintenance

•After using the tool, remove any dirt, grit, or oxide

inhibitor from the tool.

•Occasionally lubricate moving parts.

•Store the tool in its case with the ram fully retracted.

•Perform the Periodic Pressure Relief Valve Check

every 500 crimps or every 90 days, whichever comes

first.

“GO”GAUGE “NO GO”GAUGE

CHECK POINT (center depression

of the three depression side)

6. Discard the slugs.

Greenlee / A Textron Company 10 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070

1990 Hydraulic CrimpingTool

Troubleshooting

PROBLEM PROBABLE CAUSE POSSIBLE REMEDY

Ram does not advance. Air in the hydraulic system. See Air Purging and Oil Filling Procedure.

Check valve or release mechanism. Return tool to an authorized service center.

Ram advances slowly. Air in the hydraulic system. See Air Purging and Oil Filling Procedure.

Check valve or release mechanism. Return tool to an authorized service center.

Ram advances erratically. Air in the hydraulic system. See Air Purging and Oil Filling Procedure.

Ram retracts partially with Air in the hydraulic system. See Air Purging and Oil Filling Procedure.

each stroke. Check valve. Return tool to an authorized service center.

Ram does not fully advance. Hydraulic fluid level is low. See Air Purging and Oil Filling Procedure.

Ram does not fully retract. Air in the hydraulic system. See Air Purging and Oil Filling Procedure.

Reservoir is overfilled. See Air Purging and Oil Filling Procedure.

Internal binding. Return tool to an authorized service center.

Ram does not retract. Dies damaged. Return tool to an authorized service center.

Release mechanism. Return tool to an authorized service center.

Pressure builds slowly; Discharge check ball. Flush valve seat using rapid pump strokes.

handle springs back. If unit still does not work, return tool to an

authorized service center.

Pressure builds slowly; Relief valve or release mechanism. Return tool to an authorized service center.

no response.

No high pressure. Check valve. Flush valve seat using rapid pump strokes.

If unit still does not work, return tool to an

authorized service center.

Air in hydraulic system. Improper fill procedure. See Air Purging and Oil Filling Procedure.

Loose or missing reservoir plug. Replace plug.

Reservoir damaged. Replace reservoir.

Reservoir missing O-ring. Replace O-ring.

Damaged O-ring on low pressure Return tool to an authorized service center.

injector.

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